Method of forming a hex nut from a planar material

ABSTRACT

A hex nut formed from cutting and deforming a rigid planar material and having an integral attachment surface continuous with the deformable planar material allows attachment of the hex nut to any suitable surface. A rigid planar material such as a piece of flat metal is cut according to a particular pattern. The particular pattern includes each of the sides of the hex nut and one or more attachment surfaces as a continuous shape. The flat metal is then deformed, or bent, along certain lines to form a hex nut, or other polygonal shaped object. The attachment surface or surfaces, which extend from the sides of the hex nut, are then secured to a surface of a rotatable object, such as by adhesion or spot welding, or other suitable methods. In this manner, the hex nut can be engaged by a receptacle such as a wrench for rotating the hex nut and consequently, the object which is attached through the attachment surface.

BACKGROUND

[0001] Hex nuts are known which are used to secure a variety of itemsvia a threaded member such as a bolt. The hex nut includes acylindrical, threaded interior which corresponds to the threads on thethreaded member. Rotation of the hex nut about the threaded memberdrives the hex nut along the threaded member, typically towards anotherhex nut or blunt portion such as a bolt head. Securing of the itemsoccurs by evacuating a hole in the items to be secured. The hole islarger than the threaded member, yet smaller than the hex nut or bluntportion. The threaded member is inserted through the hole in each of theitems, and the hex nut rotated to drive the hex nut along the threadedmember. As the hex nut is rotated, the items are frictionally engagedbetween the hex nut and the blunt portion. As the hex nut is furtherrotated, the frictional forces become substantial, tending to compressand shear the hex nut and the items so secured, thereby securing theitems.

[0002] As the frictional forces increase, additional rotational torqueis required to continue rotating the hex nut. Often a receptacle such asa wrench is employed to engage the hex nut. The receptacle engages thesides of the hex nut in close proximity such that the hex nut cannotrotate independently while engaged in the receptacle. Such a receptacleis typically attached to a extended member such as a handle or rod. Theextended member allows additional leverage to be applied to the rotationof the hex nut via the receptacle. In this manner, the hex nut allowssubstantial rotational torque to be applied through a common receptaclesuch as a wrench.

[0003] In many contexts, however, the additional rotational torqueprovided by a hex nut would be desirable. Many items, such as automotiveoil filters, threaded fluid containers, and others, employ threadedcommunication with an item. Traditional hex nuts, however, arefreestanding objects, and cannot be used to direct rotational torque toanother object. An attempt to fasten a hex nut to an object to berotated is likely to have insufficient surface area to provideattachment sufficient to transfer the rotational torque to the object.Factors such as differences in materials and the available fasteningarea on the surface of the hex nut are likely to result in a fasteningthat is insufficient to transfer the rotational torque without shearingoff the hex nut from the surface of the object to be rotated. Further,manufacturing costs are likely to be infeasible for more substantialfastening.

[0004] Accordingly, it would be beneficial to provide an engageablemember in a hex nut or other polygonal shape which has an integralattachment surface for attachment to a rotatable object; which isfabricated from an integral, continuous material to increase strengthand reduce manufacturing cost, and which can withstand the torquegenerated from a rotating receptacle by which it is engaged.

SUMMARY

[0005] An engageable member defined by a plurality of continuous rigidsurfaces can be formed from a rigid, deformable planar material. Aplurality of linear deformations in the planar material between each ofthe rigid surfaces define a convex edge in the deformable planarmaterial, such that each of the rigid surfaces is substantially opposedto at least one other of the rigid surfaces. At least one integralattachment surface is also formed from the deformable planar materialsuch that it is continuous with at least one of the rigid surfaces andadapted to be attached to a rotatable object.

[0006] The engageable member appears as a hex nut or other polygonformed from cutting and deforming the rigid deformable planar materialand has an integral attachment surface continuous with the deformableplanar material to allow attachment of the engageable member to anysuitable surface. The rigid planar material such as flat metal is cutaccording to a particular pattern. The particular pattern includes eachof the sides of the engageable member and one or more attachmentsurfaces in a continuous shape. The flat metal is then deformed, orbent, along certain lines to form an engageable member having the shapeof a hex nut, or other polygonal shaped object. The attachment surfaceor surfaces, which extend from the sides of the hex nut, are thenattached to a surface of a rotatable object, such as by adhesive, spotwelding or other suitable method. In this manner, the hex nut can beengaged by a receptacle such as a wrench for rotating the hex nut andconsequently, the rotatable object which is attached through theattachment surface.

BRIEF DESCRIPTION OF THE DRAWINGS

[0007] The foregoing and other objects, features and advantages of theinvention will be apparent from the following more particulardescription of preferred embodiments of the invention, as illustrated inthe accompanying drawings in which like reference characters refer tothe same parts throughout the different views. The drawings are notnecessarily to scale, emphasis instead being placed upon illustratingthe principles of the invention.

[0008]FIGS. 1a-1 d show a hex shaped engageable member formed from aplaner material having elongated legs;

[0009]FIGS. 2a-2 d show a hex shaped engageable member formed from aplaner material cut in a repeatable, continuous manner;

[0010]FIGS. 3a-3 b show a hex shaped engageable member formed from aplanar material having a center portion adapted for adhesion to asurface;

[0011]FIGS. 4a-4 b show a hex shaped engageable member formed from aplanar surface having a seam offset from an edge of the hex surface;

[0012]FIG. 5 shows a square shaped engageable member with an offsetseam;

[0013]FIGS. 6a-6 f show another embodiment of an engageable memberformed from a continuous, repeatable pattern;

[0014]FIGS. 7a-7 f show a hex shaped engageable member with astrengthening bar;

[0015]FIGS. 8a-8 h show an alternate embodiment having integralpolygonal reinforcement panels on the interior of the polygon;

[0016]FIGS. 9a-9 f show another embodiment having a strengthening barand cut from a continuous, repeatable pattern;

[0017]FIGS. 10a-10 c show another embodiment in which a solidstrengthening member is inserted in the interior of the polygon;

[0018]FIGS. 11a-11 c show another embodiment in which the engageablemember is disposed inside a concave hex cavity on the interior of an oilfilter;

[0019]FIGS. 12a-12 d show another embodiment including an intermediateattachment surface; and

[0020]FIGS. 13a-13 c show the intermediate surface of FIGS. 12a-12 dwith an alternate embodiment of attachment to the engageable member.

DETAILED DESCRIPTION OF THE INVENTION

[0021] A description of preferred embodiments of the invention follows.

[0022]FIGS. 1a-1 d show a hex nut shaped engageable member havingelongated legs to facilitate attachment to a rotatable object. Referringto FIGS. 1a-1 d, the hex nut shaped engageable member 10 is shown. Theengageable member 10 is cut from a deformable planar material accordingto a predetermined pattern defining a star shape, as shown in FIG. 1a. Aplurality of elongated legs 12 a-12 f extend radially from a central hub14. The central hub 14 is hexagon shaped to correspond with the sides ofthe finished hex nut shaped engageable member shown in FIG. 1c.Alternatively, the central hub defining the finished shape could beanother polygonal shape having a plurality of substantially opposedsides, such as four or five. An alternate embodiment with a varyingnumber of sides can be engaged by a corresponding receptacle havingsides corresponding to at least two of the sides of the engageablemember, so as to prevent independent rotation of the engageable memberwhile engaged in the receptacle.

[0023]FIG. 1b shows the engageable member 10 in a partially completedstate. Referring to FIG. 1b, the elongated legs 12 a-12 b have beendeformed downward along deformable edges 16 a-16 f, thereby defining theopposed sides 20 a-20 f, corresponding to the hex shape of the centralhub 14.

[0024] Referring to FIG. 1c, the elongated legs 12 a-12 f are deformedalong deformable lines 18 a-18 f. The elongated legs 12 a-12 f aredeformed to extend radially from the central hub 14. In this manner, theelongated legs 12 a-12 f form an attachment surface adapted to besecured to a rotatable object (not shown) for rotation via the hex nutshaped engageable member 10. In a particular embodiment, shown in FIG.1d, the rotatable object is an automotive oil filter 20 attached to theelongated legs 12 a-12 f via any suitable method, such as via spot welds22. The elongated legs may define a concave surface adapted to beattached to a convex surface.

[0025] In another particular embodiment, shown in FIGS. 2a-2 d, the hexnut shaped engageable member is formed from a repeatable, continuouspattern in the deformable planar material. The repeatable, continuouspattern minimizes waste from unused portions of the deformable planarmaterial between the cutouts of the hex nut shaped engageable member.Referring to FIGS. 2a-2 d, the engageable member 30 is cut from thepattern shown in FIG. 2a. The repeatable, continuous pattern shown inFIG. 2a allows all of the deformable planar material to be utilized.Referring to FIG. 2b, a segment 40 of the deformable planar material iscut partially across along parallel lines 32. Referring to FIG. 2c, thedeformable planar material 40 is deformed along the dotted line 34,defined by a line perpendicular to the end of the cutting of theparallel lines 32, thereby forming the integral attachment surfaces 36a-36 f. The deformable planar material is then deformed along theparallel lines 32 to form outside convex edges 33 substantially evenlyspaced apart from each other and defining an interior polygon 35 withsubstantially opposed sides 20 a-20 f. In the embodiment shown, each ofthe opposed sides 20 a-20 f is disposed substantially 120° with respectto the adjacent side, thereby forming a hexagon, however other polygonscan be formed by varying the number of sides.

[0026]FIGS. 3a-3 b show a particular embodiment adapted to be attachedvia a center hub 42. A star shaped pattern is cut in the deformableplanar material, similar to that shown in FIG. 1 having shorter members44 a-44 f radiating from the center hub 42. The members 44 a-44 f aredeformed along the dotted lines 46 until disposed substantiallyperpendicular to the plane center in which hub 42 lies, forming opposedsides 48 a-48 f, as shown in FIG. 3b. As described above, a hexagonshape is defined, although other polygons could be employed by varyingthe number of members 44 radiating from the center hub 42. The centerhub 42 is adapted to be secured to a working surface of a rotatableobject by any suitable means, such as spot welding. The rotatable objectmay then be rotated by engaging two or more of the opposed sides 48 a-fwith a suitable receptacle.

[0027]FIGS. 4a-4 b shows a particular embodiment wherein thediscontinuous portion along the opposed sides is offset so as to bedisposed in the center of one of the opposed sides. By offsetting thediscontinuous portion to the center of one of the disposed sides, all ofthe deformed edges remain continuous. Providing a continuous edgepromotes strength since the edges tend to absorb much of the force whenengaged by a receptacle. Referring to FIG. 4a, an engageable member 50is formed in a configuration similar to the embodiment shown in FIGS.2a-2 d. The discontinuous portion 52, however, defined by the cutting ofthe deformable planar material, is disposed in the center between sides54 a and 54 g. Further, the discontinuous portion 52 extends betweensides 56 a and 56 g. Therefore, sides 56 a and 56 g effectively define acommon opposed side with respect to the opposed sides 56 b-56 f whichdefine the polygonal shape 58. Each of the members 54 a-54 g is adaptedfor attachment to a rotatable surface 60 such as the end side of astandard oil filter 20. In this manner, each of the edges between thesides 56 a-56 g remains continuous to increase the torque and shearwhich may be tolerated by the engageable member.

[0028]FIG. 5 shows another particular embodiment having a discontinuousportion, or seam, along one of the sides in which the interior of thepolygon is adapted to receive a square insertable member such as asocket wrench. As in FIGS. 4a-4 b, the members 54 a-54 e are secured toa rotatable surface 60, such as the end side of a standard oil filter20. The sides 56 a-56 e are oriented in an opposed manner to define afour sided polygon. The four sided polygon 62 is adapted to receive asimilarly shaped member such as a standard socket wrench. In thisembodiment the receptacle is defined by the interior of the polygon andthe engaging receptacle defined by a polygon adapted to be inserted inthe interior of the polygon 62.

[0029]FIGS. 6a-6 b show yet another embodiment in which a continuous,repeatable pattern is employed in fabricating the engageable member.Referring to FIGS. 6a and 6 b a plurality of legs 70 a-70 f are cut fromthe deformable planar material 40. A polygonal body portion 72 is alsocut from the portion between the legs 70 a-70 f. A bend line 74 isdefined on each of the legs 70 a-70 f, and corresponds to the width ofthe polygonal body portion 72. Referring to FIG. 6c, each of the legs 70is deformed in a perpendicular manner to form an attachment portion 76.Referring to FIGS. 6b and 6 d, the polygonal body portion 72 is deformedat substantially equal distances and angles along bend lines 78 to forma polygonal shape 80 comprising a plurality of opposed sides 20 a-20 f.Each of the opposed sides 20 a-20 f has a width corresponding to thewidth of the legs 70 a-70 f. Referring to FIG. 6e, each of the legs 70a-70 f is attached to a corresponding one of the opposed sides 20 a-20 fof the polygonal body portion 72 at the attachment portion 76. The legsmay be attached by any suitable means, such as adhesive or spot welding,and may be attached to either the interior or exterior of the polygonalshape 80. Referring to FIG. 6f, the resulting engageable member 82 isstrengthened from the double walls comprised of the opposed sides 20a-20 f of the polygonal body portion 72 and the attachment portion 76 oflegs 70 a-70 f.

[0030]FIGS. 7a-7 f shows an alternate embodiment employing astrengthening bar to strengthen the opposed sides of the hex shape.Referring to FIGS. 7a and 7 b, a plurality of portions 90 are cut from asheet of the deformable planar material 40. A waste portion 92 betweenthe portions 90 is discarded. Each portion 90 has legs 94 a-94 fextending from a spine 96. The spine includes an integral, continuousstrengthening bar 98 defined by the material extending beyond the legs94. Referring to FIGS. 7c and 7 d, the strengthening bar 98 is deformed180° back over the spine 96, thereby forming a double walled portion100. The double walled portion 100 is then deformed along the cut lines104 of legs 94 a-94 f into a polygonal shape 80 having opposed sides 102a-102 f defined by the legs 94 a-94 f. Referring to FIG. 7f, the legs 94a-94 f are deformed outward so as to form an attachment surface to beattached to an object for rotation. In this manner, the double walledportion 100, when deformed in to the polygonal shape 80 provides astrengthened hex nut shape so as to absorb additional shear andcompressive forces against the opposed sides 102 a-102 f when engaged byan engaging member.

[0031]FIGS. 8a-8 h show a particular embodiment having polygonal shapedreinforcement panels. Referring to FIGS. 8a and 8 b, a sheet ofdeformable planar material 40 is cut to form a plurality of portions110. A waste area 112 between the portions 110 is discarded. Each of theportions 110 has at least one integral polygonal reinforcement panel114. The reinforcement panels 114 are continuous with the portions 110via spacer legs 116, 118. The spacer legs include short spacer legs 116and long spacer legs 118, and vary in length to offset and accommodate aplurality of the reinforcement panels as will be described below.Referring to FIGS. 8c, 8 d and 8 e, the reinforcement panels 114 aredeformed at the corresponding spacer leg 116, 118 to dispose thereinforcement panels 114 perpendicular to the portion 110 at offsetheights as defined by the spacer legs 116 and 118. Referring to FIGS.8f, 8 g and 8 h, the portion 110 is deformed into a polygonal shape asdescribed above to define opposed wall surfaces 126. A plurality of legs124 defined by each of the sides of the polygon is then deformed outwardto provide an attachment surface to an object to be rotated.

[0032]FIGS. 9a-9 f show another embodiment cut from a continuous,repeatable pattern and having double wall segments. Referring to FIGS.9a and 9 b, a continuous, repeatable pattern similar to that of FIG. 6ais cut in a sheet of deformable planar material 40 to yield a cutportion 130. Double wall segments 132, continuous and integral with theportion 130, are each folded 180° to form a double wall 134. The doublewall is then deformed as above into a polygonal shape such as a hexagon136. The legs 138 are then deformed at the edge of the double wall 134to provide an attachment surface to a rotatable object.

[0033]FIGS. 10a-10 c show another embodiment in which a solidstrengthening member is inserted in the interior of the resultingpolygon. Referring to FIGS. 10a-10 c, an elongated metal rod 150 has apolygonal cross-section such as a hexagon. The rod 150 has a diameterslightly smaller than that defined by the opposed sides 156 of theengageable member 158 so as to be slideably inserted in close tolerancewith the opposed sides 156. A portion 152 is cut off of the rod 150,typically a length less than the diameter of the rod 150. The portion152 is inserted in the interior of the polygon 154 defined by theopposed sides 156 of the engageable member 158 to form a solidstrengthening member 160. The solid strengthening member 160 is securedto the interior of the polygon 154 by any suitable attachment such asspot welds 162. The solid strengthening member 160 therefore providessupport to the engageable member 158 to resist compression and shearforces as the engageable member 158 is engaged and rotated.

[0034]FIGS. 11a-11 c show another embodiment in which the engageablemember is disposed inside a concave cavity on the interior of an oilfilter. Referring to FIGS. 11a-11 c, a concave polygonal shaped cavityis formed on one end of an attachment surface 166 such as the closed endof an oil filter. The concave cavity is slightly larger and of a similarshape to the polygon defined by the opposed sides of the engageablemember 168. The engageable member 168 is inserted such that the opposedsides are in close tolerance with the sides of the concave cavity 164.The engageable member is attached to the attachment surface 166 via oneor more legs 170. In this manner the opposed sides of the engageblemember form a double wall surface with the sides of the polygonal cavityso as to absorb shear and compressive forces when engaged.

[0035]FIGS. 12a-12 d show another embodiment including an intermediateattachement surface. The intermediate attachment surface 180 is adaptedto mate with the attachment surface of the engageable member using anysuitable embodiment described above, such as the engageable member 30shown in FIG. 2d. The intermediate attachment surface 180 has a greaterattachment area 182 than the attachment surface 184 of the engageablemember 30. In this manner, the engageable member 30 may be attached tothe intermediate attachement surface 180, and then the intermediateattachment surface may be attached to the rotatable object 20 such as anoil filter. Since the intermediate attachment surface 180 has a greaterattachment area 182, it provides greater torque to be transferred fromthe engageable member 30 to the rotatable object 20. Attachment methodswhich may have compromised the surface of the rotatable object 20, suchas welding, may now be distributed over a larger area 184 on therotatable object 20.

[0036]FIGS. 13a-13 c show the intermediate attachment surface having anaperture formed from cut-out flaps. Referring to FIGS. 13a-13 c, a starshaped cutout 188 is made in the intermediate attachment surface 180.The star defines the cut-out flaps 190, which are deformed substantiallyperpendicular to the intermediate attachment surface. The cut-out flapsare then attached to the engageable member 30. In this manner, a greaterattachment surface area on the engageable member is effected.

[0037] While this invention has been particularly shown and describedwith references to preferred embodiments thereof, it will be understoodby those skilled in the art that various changes in form and details maybe made therein without departing from the scope of the inventionencompassed by the appended claims. Accordingly, the invention is notintended to be limited except by the following claims.

What is claimed is:
 1. A engageable member comprising: a plurality ofcontinuous rigid surfaces formed from a deformable planar material; aplurality of linear deformations in the continuous material between eachof the rigid surfaces defining a convex edge in the deformable planarmaterial, such that each of the rigid surfaces is substantially opposedto at least one other of the rigid surfaces; and at least one integralattachment surface continuous with at least one of the rigid surfacesand adapted to be attached to a rotatable object.
 2. The engageablemember of claim 1 wherein the engageable member is operable to beengaged and rotated by a receptacle.
 3. The engageable member of claim 2wherein the attachment to the rotatable object is adapted to withstandshear forces from rotation of the receptacle.
 4. The engageable memberof claim 1 wherein the continuous rigid surfaces define a polygon. 5.The engageable member of claim 4 wherein each of the continuous rigidsurfaces is substantially opposed to a rigid surface on an opposite sideof the polygon.
 6. The engageable member of claim 5 wherein thereceptacle is adapted to contact at least two of the opposed rigidsurfaces corresponding to opposite sides of the polygon.
 7. Theengageable member of claim 1 wherein the integral attachment surfacefurther comprises continuous elongated legs formed by a lineardeformation of the deformable planar material along an axissubstantially perpendicular to the convex edge of an adjacent rigidsurface.
 8. The engageable member of claim 4 wherein the integralattachment surface further comprises a continuous surface integral withthe sides of the polygon and substantially perpendicular to each of theopposed rigid surfaces.
 9. The engageable member of claim 1 wherein thecontinuous rigid surfaces comprise a continuous repeatable pattern inthe deformable, resilient planar material.
 10. The engageable member ofclaim 5 wherein at least one of the opposed sides has a discontinuousnotch.
 11. The engageable member of clam 1 wherein the integralattachment surface is concave and adapted to be attached to a convexsurface.
 12. The engageable member of claim 4 wherein the polygon is ahexagon.
 13. The engageable member of claim 4 further comprising adiscontinuous seam along the sides of the polygon.
 14. The engageablemember of claim 13 wherein the discontinuous seam is on one of theopposed sides.
 15. The engageable member of claim 5 further comprisingan integral strengthening bar extending from one of the opposed sides,wherein the strengthening bar is deformed in a pattern corresponding tothe opposed sides such that the strengthening bar is coplaner with eachof the opposed sides.
 16. The engageable member of claim 5 wherein thepredetermined pattern includes at least one integral polygonal tab, thepolygonal tab corresponding to the polygon defined by the opposed sides,wherein the polygonal tab is deformed such that it is disposed in theinterior of the polygon.
 17. The engageable member of claim 5 furthercomprising a double wall, wherein the double wall is defined bydeforming a portion of the deformable planar material along a portioncorresponding to the opposed sides such that the opposed sides arecomprised of multiple coplanar portions of the deformable planarmaterial.
 18. The engageable member of claim 17 wherein the double wallis defined by a plurality of parallel cuts, wherein each of the parallelcuts is substantially colinear with an edge of the polygon.
 19. Theengageable member of claim 5 wherein a solid strengthening member isinserted into the interior defined by the opposed sides of the polygon.20. The engageable member of claim 19 wherein the solid strengtheningmember is slideably inserted and in close tolerance with the opposedsides of the polygon.
 21. The engageable member of claim 20 wherein thesolid strengthening member is attached to the opposed sides of thepolygon.
 22. The engageable member of claim 21 wherein the attaching isvia spot welding.
 23. The engageable member of claim 5 wherein thepolygon defined by the opposed sides is adapted to be disposed in theinterior of a concave cavity formed by deforming a surface in a similarshape as the polygon.
 24. A method of forming an engageable membercomprising: providing a rigid, deformable planar material; cutting theplanar material according to a predetermined pattern; and deforming theplanar material to form an interior having a plurality of substantiallyopposed sides adapted to engage a receptacle, wherein the cuttingaccording to the predetermined pattern includes an integral attachmentsurface adapted to be secured via an attachment to a rotatable object.25. The method of claim 24 wherein the engageable member is operable tobe engaged and rotated by a receptacle.
 26. The method of claim 25wherein the attachment to the rotatable object is adapted to withstandshear forces from rotation of the receptacle.
 27. The method of claim 24wherein the substantially opposed sides define a polygon.
 28. The methodof claim 24 further comprising attaching the engageable member to arotatable object adapted to be rotated about an axis defined by thecenter of the polygon by engaging the opposed sides of the polygon. 29.The method of claim 28 wherein the attaching further comprises spotwelds.
 30. The method of claim 28 wherein the attaching furthercomprises a resilient adhesive.
 31. The method of claim 24 wherein thepredetermined pattern defines a continuous, repeatable pattern from acontinuous sheet.
 32. The method of claim 24 wherein the cuttingaccording to the predetermined pattern defines the integral attachmentsurface as a plurality of elongated legs adapted to extend radially froma central hub defined by the substantially opposed sides.
 33. The methodof claim 32 wherein deforming further comprises deforming each of theelongated legs as a continuous extension of the substantially opposedsurfaces such that the elongated legs extend radially from an integralcentral hub upon deformation of the legs at a union of the elongatedlegs and the substantially opposed sides.
 34. The method of claim 24wherein the predetermined pattern comprises a star defined by a centralpolygon and elongated surfaces radiating perpendicular to each side ofthe polygon.
 35. The method of claim 27 wherein deforming furthercomprises deforming along a line defined by the edges of a polygon. 36.The method of claim 27 wherein the integral attachment surface is thepolygon.
 37. The method of claim 24 wherein cutting further comprisescutting along a plurality of parallel lines wherein the parallel linesdefine the opposed surfaces, and wherein deforming further comprisesdeforming along the parallel lines.
 38. The method of claim 37 whereindeforming further comprises deforming along a line substantiallyperpendicular to the parallel lines at lines defined by the end of thecutting.
 39. The method of claim 24 wherein deforming further comprisesdeforming the opposed sides such that a discontinuous seam is formedalong one of the opposed sides.
 40. The method of claim 24 whereindeforming further comprises deforming such that the discontinuous seamis substantially centered on one of the opposed sides.
 41. The method ofclaim 24 wherein cutting according to a predetermined pattern furthercomprises cutting an integral strengthening bar extending from one ofthe opposed sides, and wherein deforming further comprises deformingsuch that the strengthening bar is deformed in a pattern correspondingto the opposed sides and that the strengthening bar is coplaner witheach of the opposed sides.
 42. The method of claim 24 wherein cuttingfurther comprises cutting such that the predetermined pattern includesat least one integral polygonal tab, the polygonal tab corresponding tothe polygon defined by the opposed sides, wherein the polygonal tab isdeformed such that it is disposed in the interior of the polygon. 43.The method of claim 24 wherein at least one of the opposed sides furthercomprises a double wall, wherein the double wall is defined by deforminga portion of the deformable planar material along a portioncorresponding to the opposed sides such that the opposed sides arecomprised of multiple coplanar portions of the deformable planarmaterial.
 44. The method of claim 43 wherein the double wall is definedby a plurality of parallel cuts, wherein each of the parallel cuts issubstantially colinear with an edge of the polygon.
 45. The method ofclaim 27 wherein a solid strengthening member is inserted into theinterior defined by the opposed sides of the polygon.
 46. The method ofclaim 45 further comprising slideably inserting the solid strengtheningmember into the interior wherein the solid strengthening member is inclose tolerance with the opposed sides of the polygon.
 47. The method ofclaim 46 further comprising attaching the solid strengthening member tothe opposed sides of the polygon.
 48. The method of claim 47 wherein theattaching is via spot welding.
 49. The method of claim 24 furthercomprising deforming a surface of a rotatable object in a shape similarto the polygon defined by the opposed sides, and receiving theengageable member therein.
 50. The method of claim 24 further comprisingattaching the engageable member to an intermediate attachment surfacewherein the intermediate attachment surface is adapted to distributetorque to the rotatable object.
 51. The method of claim 50 wherein theintermediate attachment surface has a greater attachment area than theattachment surface of the engageable member.
 52. The engageable memberof claim 1 wherein the surface of the rotatable object has a cavitydeformed in a shape similar to the engageable member.
 53. The engageablemember of claim 1 further comprising an intermediate attachment surfaceadapted to be attached to the attachment surface of the engageablemember and further adapted to be attached to the rotatable object. 54.The engageable member of claim 53 wherein the intermediate attachmentsurface has a greater attachment area than the attachment surface of theengageable member.
 55. The engageable member of claim 53 wherein theintermediate attachment surface has a plurality of cut-out flaps definedby cuts in the intermediate attachment surface and deformedsubstantially perpendicular to the intermediate attachment surface. 56.A engageable member comprising: a plurality of continuous rigid surfacesformed from a deformable planar material; a plurality of lineardeformations in the continuous material between each of the rigidsurfaces defining a convex edge in the deformable planar material, suchthat each of the rigid surfaces is substantially opposed to at least oneother of the rigid surfaces; and a plurality of attachment surfacesextending from and substantially perpendicular to at least one of therigid surfaces and adapted to be attached to a rotatable object, whereineach of the attachment surfaces are joined to one of the rigid surfacesin a coplanar manner such that a double wall is formed.
 57. Theengageable member of claim 56 wherein the rigid surfaces define apolygon and the double walls comprise the sides of the polygon.
 58. Anengagement device comprising a polygonal receptacle having a pluralityof pairs of opposed sides, each of the pairs of opposed sides adapted tobe engaged; an integral central hub connected to at least one of theopposed sides, wherein the opposed sides and the central hub arecomprised of a continuous, homogeneous material and the integral centralhub forms a deformable union substantially perpendicular to at least oneof the opposed sides.